KTM 390 ADVENTURE 2022 Manual

SETUP INSTRUCTIONS 2022
390 ADVENTURE
Art. no. 3214692en

INTRODUCTION
*3214692en*
3214692en
03/2022
INTRODUCTION
Perform the work described in these setup instructions before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
These setup instructions were written to correspond to the latest state of this model series. We reserve the right
to make modifications in the interest of technical advancement without at the same time updating these setup
instructions.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop
are not specified here. It is assumed that the work will be performed by a fully trained mechanic.
All specifications contained herein are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right
to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc.,
without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop produc-
tion of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from fig-
ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that
does not belong to the regular scope of supply.
© 2022 KTM Sportmotorcycle GmbH, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission
of the copyright owner.
ISO 9001(12 100 6061)
KTM applies quality assurance processes that lead to the highest possible product quality as
defined in the ISO 9001 international quality management standard.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria
This document is valid for the following models:
390 ADVENTURE EU (F5303V5, F5303V6)
390 ADVENTURE B.D. EU (F5303V7, F5303V8)
390 ADVENTURE B.D. 2 EU (F5303V7L, F5303V8L)
390 ADVENTURE JP (F5386V5, F5386V6)
390 ADVENTURE UK (F5322V5, F5322V6)
390 ADVENTURE US (F5375V5, F5375V6)
390 ADVENTURE AR (F5342V5, F5342V6)
390 ADVENTURE ASEAN (F5388V5, F5388V6)
390 ADVENTURE CN (F5387V5, F5387V6)
390 ADVENTURE CO (F5341V5, F5341V6)
390 ADVENTURE PH (F5382V5, F5382V6)

1 MEANS OF REPRESENTATION
2
1.1 Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Indicates a voltage measurement.
Indicates a current measurement.
Indicates a resistance measurement.
Indicates the end of an activity including potential rework.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.
Name®Indicates a protected name.
Brand™ Indicates a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which
are explained in the glossary.

SETUP 2
3
2.1 Transport mode
H02713-01
This vehicle was blocked for transport in the software.
To operate the vehicle, the vehicle electronics must be enabled.
This process is conducted during initial setup in KTM Dealer.net.
Enabling ensures that the initial setup in KTM Dealer.net is docu-
mented.
Enabling can be performed either temporarily, e.g. for a test ride,
or permanently for vehicle handover.
Info
Make sure that the vehicle is permanently enabled before
handing it over to the customer.
2.2 Diagnostics connector
A00702-10
Diagnostics connector 1is located under the passenger seat.
2.3 Unpacking and setting up the vehicle
S04201-01
–Remove the straps and the box.
S04202-01
–Remove the adhesive tape in the upper area of the motorcycle.

2 SETUP
4
S04203-01
–Roll down the film at the sides.
Info
To avoid damaging the motorcycle during unpacking,
leave the other films on the vehicle until you have fin-
ished work on the vehicle.
–Remove the separate enclosure and unpack it. Check that the
scope of supply is complete using the enclosed packing list.
Info
The procedure for missing components is described in
the Customer Service Manual.
–Check the vehicle for transport damage.
Info
The procedure in the event of transport damage is
described in the Customer Service Manual.
S04204-01
Warning
Danger of accidents A repaired handlebar poses a
safety risk.
If the handlebar is bent or straightened, the mate-
rial becomes fatigued. The handlebar may break as a
result.
–Change the handlebar if the handlebar is damaged
or bent.
–Position the handlebar.
Info
Make sure the cables and wiring are positioned cor-
rectly.
–Position the handlebar clamps.
The markings on the handlebar clamps point to the front.
–Mount the screws, but do not tighten them yet.
–First, screw the screws onto the longer, higher side of the han-
dlebar supports so that both parts touch.
–Tighten the screws evenly.
Guideline
Screw, handlebar
clamp
M8 20 Nm (14.8 lbf ft)
The lettering on the handlebar is in the middle of the han-
dlebar clamp.

SETUP 2
5
S04206-01
–Check that the vulcanized part of the front brake line is hooked
into the bracket below the fuel tank.
The brake line is correctly hooked into the bracket, as
shown in the figure.
The brake line is not correctly hooked into the bracket.
–Hook the brake line into the bracket as shown in the
figure.
Info
If the vulcanized part of the front brake line is not
hooked into the bracket, the brake line can be
squeezed when turning.
S04205-01
–Attach the outer clutch cable.
S04207-01
–Plug in the connector of the brake light switch.
M01981-10
Condition
Cover is not mounted, but no holder for navigation devices
present
–Position cover 1, mount screws 2on both sides and
tighten.
Guideline
Remaining screws,
chassis
M5 5 Nm (3.7 lbf ft)
S04208-01
–Fit the handguard and rear mirror on both sides.
Guideline
Nut, left rear mirror M10x1.25 16 Nm (11.8 lbf ft)
Nut, right rear mirror M10LHx1.25 16 Nm (11.8 lbf ft)
–Position all controls in their exact positions on the handlebar.
Tighten all screws.
–Mount the windshield.
Guideline
Remaining screws,
chassis
M5 5 Nm (3.7 lbf ft)

2 SETUP
6
H03807-10
–Make sure that the clutch cable is attached to the clutch
release lever and secured.
–Check the clutch lever play. ( p. 8)
–Carefully loosen and remove the tension belt over the link fork.
Info
An assistant prevents the motorcycle from falling over.
–Carefully loosen and remove the tension belts around the lower
triple clamp.
The vehicle is released at the front.
–Together with an assistant, take the vehicle off the pallet.
–Remove the passenger seat. ( p. 9)
S04209-01
–Take the tool set out of the separate enclosure and store it in
the storage compartment under the passenger seat using the
rubber straps provided in the tool set.
–Remove the front rider's seat. ( p. 9)
–Remove spare key and KEYCODECARD from under the seat and
keep in a safe place for the handover.
Warning
Risk of injury Battery acid and battery gases cause
serious chemical burns.
–Keep 12 V batteries out of the reach of children.
–Wear suitable protective clothing and safety
glasses.
–Avoid contact with battery acid and battery gases.
–Keep sparks or open flames away from the 12 V
battery.
–Only charge 12 V batteries in well-ventilated
rooms.
–Rinse the affected area immediately with plenty of
water in the event of contact with the skin.
–Rinse eyes with water for at least 15 minutes and
consult a doctor immediately if battery acid and
battery gases get into the eyes.
–Fill the 12 V battery.
Info
Read the notes in the 12 V battery accessory pack.
–Charge the 12-V battery. ( p. 10)
Guideline
The 12-V battery must be fully charged before it is handed
over to the customer.
Info
The first charging process may take longer with a new
12-V battery.
–Install the 12-V battery. ( p. 12)

SETUP 2
7
–Remove the remaining film, padding, the corrugated card-
board, and the other packaging material.
–Refuel. ( p. 15)
–Check the headlight setting. ( p. 16)
–Prepare the vehicle according to the specifications in
the KTM Dealer.net for handover to the customer.
Info
Transport mode must be deactivated to be able to start
the motorcycle.

3 WORK
8
3.1 Checking the clutch lever play
Note
Clutch damage If there is no free travel by the clutch lever, the clutch will begin to slip.
–Check the free travel of the clutch lever each time before using the motorcycle.
–Adjust the free travel of the clutch lever when necessary in accordance with the specification.
S04142-12
–Check the clutch lever for smooth operation.
–Move the handlebar to the straight-ahead position.
–Pull the clutch lever until resistance is perceptible, and deter-
mine the play in the clutch lever A.
Clutch lever play A1 … 3 mm (0.04 …
0.12 in)
» If the clutch lever play does not meet the specified value:
–Adjust play in the clutch lever. ( p. 8)
–Move the handlebar to and fro over the entire steering range.
The clutch lever play must not change.
» If the clutch lever play changes:
–Check the routing of the clutch cable.
3.2 Adjusting play in the clutch lever
S04175-10
–Move the handlebar to the straight-ahead position.
–Push back sleeve 1.
–Loosen lock nut 2.
–Adjust the play in the clutch level Aby turning adjusting
screw 3.
Guideline
Clutch lever play A1 … 3 mm (0.04 …
0.12 in)
–Tighten lock nut 2.
–Position bellows 1.

WORK 3
9
3.3 Removing the passenger seat
H01991-10
–Insert the ignition key in seat lock 1and turn it clockwise.
–Raise the rear of the seat, push it towards the rear, and lift it
off.
–Remove the ignition key from the seat lock.
3.4 Mounting the passenger seat
H01992-01
–Attach hooks 1on the passenger seat to seat mounting 2
on the subframe, and lower it at the rear while pushing for-
ward.
–Press passenger seat downward until it clicks into place.
Warning
Danger of accidents The seat can come loose from the
anchoring if it is not mounted correctly.
–After assembly, check whether the seat is correctly
locked and cannot be pulled up.
–Finally, check that the passenger seat is correctly mounted.
3.5 Removing the front rider's seat
Preparatory work
–Remove the passenger seat. ( p. 9)
H01993-01
Main work
–Raise the rear of the front rider's seat, pull it towards the rear,
and remove it upwards.

3 WORK
10
3.6 Mounting the front rider's seat
H01994-01
Main work
–Attach the front rider's seat in area Aand lower at the rear.
–Finally, check that the front rider's seat is correctly mounted.
Finishing work
–Mount the passenger seat. ( p. 9)
3.7 Charging the 12-V battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–Keep 12 V batteries out of the reach of children.
–Wear suitable protective clothing and safety glasses.
–Avoid contact with battery acid and battery gases.
–Keep sparks or open flames away from the 12 V battery.
–Only charge 12 V batteries in well-ventilated rooms.
–Rinse the affected area immediately with plenty of water in the event of contact with the skin.
–Rinse eyes with water for at least 15 minutes and consult a doctor immediately if battery acid and
battery gases get into the eyes.
Note
Environmental hazard 12 V batteries contain environmentally hazardous materials.
–Do not dispose of 12 V batteries as household waste.
–Dispose of 12 V batteries at a collection point for used batteries.
Note
Environmental hazard Hazardous substances cause environmental damage.
–Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
Even when there is no load on the 12-V battery, it discharges steadily each day.
The charging level and the method of charging are very important for the service life of the 12-V battery.
Rapid recharging with a high charging current shortens the service life of the battery.
If the charging current, charging voltage, or charging time is exceeded, electrolyte escapes through the
safety valves. This reduces the capacity of the 12-V battery.
If the 12-V battery is depleted by repeated starting, the 12-V battery must be charged immediately.
If the 12-V battery is left in a discharged state for an extended period, it will become deeply discharged
and sulfating occurs, destroying the battery.
The 12-V battery is maintenance-free. The acid level does not have to be checked.
Preparatory work
–Remove the passenger seat. ( p. 9)

WORK 3
11
–Remove the front rider's seat. ( p. 9)
–Disconnect the negative cable of the 12-V battery. ( p. 11)
311910-10
Main work
–Connect a battery charger to the 12-V battery. Adjust the bat-
tery charger.
EU battery charger XCharge‑professional (00029095050)
Alternative 1
US battery charger XCharge‑professional
(00029095051)
Alternative 2
UK battery charger XCharge‑professional
(00029095052)
Info
Follow the instructions of the charger and the manual.
–Disconnect the battery charger after charging the 12-V battery.
Guideline
The charging current, charging voltage, and charging time
must not be exceeded.
Recharge the 12-V battery
regularly when the motorcy-
cle is not being used
3 months
Finishing work
–Connect the negative cable of the 12-V battery. ( p. 12)
–Mount the front rider's seat. ( p. 10)
–Mount the passenger seat. ( p. 9)
–Set time and date. ( p. 13)
3.8 Disconnecting the negative cable of the 12-V battery
Preparatory work
–Remove the passenger seat. ( p. 9)
–Remove the front rider's seat. ( p. 9)
S04165-12
Main work
–Disconnect negative cable 1of the 12-V battery.

3 WORK
12
3.9 Connecting the negative cable of the 12-V battery
S04165-12
Main work
–Connect negative cable 1of the 12-V battery.
Finishing work
–Mount the front rider's seat. ( p. 10)
–Mount the passenger seat. ( p. 9)
–Set time and date. ( p. 13)
3.10 Installing the 12-V battery
S04166-11
Main work
–Position the 12-V battery in the battery compartment.
12-V battery (ETZ‑9‑BS)
–Close rubber strap 1and attach rubber strap 2.
–Position positive cable 3and mount and tighten the screw.
–Position positive terminal cover 4.
S04165-11
–Position negative cable 5and mount and tighten the screw.
–Position the holding bracket, mount and tighten screws 6.
Guideline
Screw, cross connec-
tor
M6 15 Nm (11.1 lbf ft)
Finishing work
–Mount the front rider's seat. ( p. 10)
–Mount the passenger seat. ( p. 9)
–Set time and date. ( p. 13)

WORK 3
13
3.11 Setting the time and date
Condition
The motorcycle is stationary.
V01172-01
–Press the SET button when the menu is closed.
–Press UP or DOWN button until Preferences appears. Press
the SET button to open the menu.
–Press the UP or DOWN button until Clock/Date is highlighted.
Press the SET button to open the menu.
V01173-01
Setting the clock
–Press UP or DOWN button until the time is marked.
–Press the SET button.
The hour flashes and is underlined.
–Press UP or DOWN button until the current hour is set.
–Press the SET button.
The minutes flash and are underlined.
–Press UP or DOWN button until the current minute is set.
–Press the SET button.
The time is stored.
V01174-01
Setting the date
–Press UP or DOWN button until the date is marked.
–Press the SET button.
The day flashes and is underlined.
–Press UP or DOWN button until the current day is set.
–Press the SET button.
The month flashes and is underlined.
–Press UP or DOWN button until the current month is set.
–Press the SET button.
The year flashes and is underlined.
–Press UP or DOWN button until the current year is set.
–Press the SET button.
The date is stored.
3.12 Opening fuel tank filler cap
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.

3 WORK
14
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
–Keep fuels correctly in a suitable canister, and out of the reach of children.
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to enter the groundwater, the soil, or the sewage system.
S04127-10
–Lift cover 1of the fuel tank filler cap and insert the ignition
key into the lock.
Note
Danger of damage The ignition key may break if overloaded.
Damaged ignition keys must be replaced.
–Push down on the fuel tank filler cap to take pressure off
the ignition key.
–Turn the ignition key 90° clockwise.
–Lift the fuel tank filler cap.
3.13 Closing the fuel tank filler cap
A00705-10
Warning
Fire hazard Fuel is highly flammable, toxic and a
health hazard.
–Check that the fuel tank filler cap is locked cor-
rectly after closing.
–Change your clothing if fuel spills on them.
–Rinse the affected area immediately with plenty of
water in the event of contact with the skin.
–Fold down the fuel tank filler cap.
–Turn the ignition key 90° clockwise.
–Push down the fuel tank filler cap and turn the ignition key
counterclockwise until the fuel tank filler cap lock engages.
–Remove the ignition key and close the cover.

WORK 3
15
3.14 Refueling
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
Note
Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged.
In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in
problems with the fuel system.
–Refuel only with clean fuel that meets the specified standards.
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to enter the groundwater, the soil, or the sewage system.
S04133-10
–Switch off the engine.
–Open fuel tank filler cap. ( p. 13)
–Fill the fuel tank with fuel up to the lower edge 1of the fuel
filler.
Total fuel tank
capacity, approx.
14.5 l
(3.83 US gal)
Super unleaded
(ROZ 95)
( p. 18)
–Close the fuel tank filler cap. ( p. 14)

3 WORK
16
3.15 Checking the headlight setting
400726-10
–Park the vehicle on a horizontal surface in front of a light-
colored wall and make a mark at the height of the center of
the low beam headlight.
–Make another mark at a distance Bunder the first marking.
Guideline
Distance B5 cm (2 in)
–Position the vehicle vertical to the wall at distance Afrom
the wall and switch on the low beam.
Guideline
Distance A5 m (16 ft)
–The rider now mounts the motorcycle with luggage and passen-
ger if applicable.
–Check the headlight setting.
The light-dark boundary must be exactly on the lower mark-
ing when the motorcycle is ready to be operated with the
rider mounted along with any luggage and a passenger if
applicable.
» If the boundary between light and dark does not meet
specifications:
–Adjust the headlight range. ( p. 16)
3.16 Adjusting the headlight range
Preparatory work
–Check the headlight setting. ( p. 16)
A00701-10
Main work
–Turn adjusting screw 1to adjust the headlight range.
Info
Turn clockwise to increase the headlight range; turn
counterclockwise to reduce the headlight range.
If you have a payload, you may have to correct the
headlight range.
Screw 1also secures the headlight. Ensure the screw
is always screwed in far enough.
400726-11
–Set the headlight to marking B.
Guideline
The light-dark boundary must lie exactly on lower mark-
ing Bwhen the motorcycle is ready to operate with the
rider mounted along with any luggage and a passenger if
applicable.

TECHNICAL DATA 4
17
4.1 Chassis tightening torques
Screw, chain guard EJOT PT®K60x30 3 Nm (2.2 lbf ft)
Screw, tail light M4 2 Nm (1.5 lbf ft)
Remaining screws, chassis M5 5 Nm (3.7 lbf ft)
Screw, chain guard M5 7 Nm (5.2 lbf ft)
Loctite®243™
Screw, compensating tank cap
lock, rear brake
M5 9 Nm (6.6 lbf ft)
Screw, foot brake lever stub M5 5 Nm (3.7 lbf ft)
Loctite®243™
Nut, foot brake lever adjustment M6 10 Nm (7.4 lbf ft)
Nut, shift rod M6 6 Nm (4.4 lbf ft)
Remaining nuts, chassis M6 15 Nm (11.1 lbf ft)
Remaining screws, chassis M6 9 Nm (6.6 lbf ft)
Screw, cross connector M6 15 Nm (11.1 lbf ft)
Screw, engine guard M6 9 Nm (6.6 lbf ft)
Loctite®243™
Screw, engine guard retaining
bracket
M6 9 Nm (6.6 lbf ft)
Loctite®243™
Screw, shift lever linkage M6 11 Nm (8.1 lbf ft)
Loctite®243™
Screw, wheel speed sensor holder M6 8 Nm (5.9 lbf ft)
Nut, rear sprocket M8 38 Nm (28 lbf ft)
Remaining nuts, chassis M8 30 Nm (22.1 lbf ft)
Screw, fork stub M8 15 Nm (11.1 lbf ft)
Screw, front brake disc M8 29 Nm (21.4 lbf ft)
Loctite®243™
Screw, front wheel spindle M8 25 Nm (18.4 lbf ft)
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft)
Screw, passenger footrest unit M8 20 Nm (14.8 lbf ft)
Loctite®243™
Screw, rear brake disc M8 29 Nm (21.4 lbf ft)
Loctite®243™
Screw, front brake caliper M8x1 30 Nm (22.1 lbf ft)
Loctite®243™
Nut, engine bearer M10 48 Nm (35.4 lbf ft)
Loctite®243™
Remaining nuts, chassis M10 50 Nm (36.9 lbf ft)
Screw, handlebar support M10 40 Nm (29.5 lbf ft)
Fitting, shock absorber, bottom M10x1.25 50 Nm (36.9 lbf ft)
Loctite®243™
Screw, top shock absorber M10x1.25 50 Nm (36.9 lbf ft)
Loctite®243™
Nut, rear wheel spindle M14x1.5 100 Nm (73.8 lbf ft)
Nut, swingarm pivot M14x1.5 100 Nm (73.8 lbf ft)
Screw, steering head, top M16x1.5 53 Nm (39.1 lbf ft)

5 SUBSTANCES
18
Super unleaded (ROZ 95)
Standard/classification
–DIN EN 228 (ROZ 95)
Guideline
–Only use super unleaded fuel that matches or is equivalent to the specified standard.
–Fuel with an ethanol content of up to 10% (E10 fuel) is safe to use.
Info
Do not use fuel containing methanol (e.g., M15, M85, M100) or more than 10% ethanol (e.g., E15,
E25, E85, E100).